JP3219661B2 - Decorative formwork for concrete, concrete product using the same, and method for producing concrete product - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a decorative formwork for concrete suitable for manufacturing a concrete product having an uneven pattern on its surface, a concrete product manufactured using the formwork, and a method for manufacturing a concrete product. More specifically, the present invention relates to a decorative mold for concrete in which an irregular pattern of an arbitrary shape can be easily formed and recyclable, a concrete product manufactured using the mold, and a method for manufacturing the same.

[0002]

2. Description of the Related Art In recent years, there has been a general tendency to improve the aesthetics of buildings and sidewalks by giving an uneven pattern to the concrete surface. It is actively manufactured.

Further, not only flat concrete products, but also concrete products having curved surfaces, such as columns having a curved surface and decorative panels having a gentle curvature such as a corrugated shape, are increasing in demand. .

Conventionally, as a method of forming a concavo-convex pattern on the surface of concrete, generally, a decorative concrete frame made of resin and having a concavo-convex pattern formed on the bottom surface in advance is used.
This resin-made decorative form is formed of a material such as a resin such as styrene foam or urethane and a fiber reinforced resin (FRP) in which these resins are filled with reinforcing fibers. In most cases, these hard resin molds are used by purchasing an existing decorative mold.

[0005] Above all, a decorative mold using styrofoam has a low resin strength, so that it is damaged when removed from the mold, has poor workability, and is disposable. In addition, disposal of styrofoam waste material poses a problem. In addition, the urethane-made decorative formwork can be reused, but the concrete release property is poor, and cement paste is successively adhered to the formwork surface due to repeated concrete placement, and sharp uneven patterns are formed on the concrete surface. It is difficult to form, and the number of reuse is only about 10 to 20 times.

Further, as a method for forming an uneven pattern on the surface of concrete having a curved surface, generally, a resin-made decorative form in which an uneven pattern is formed in advance on the surface is converted into a concrete form having a steel curvature. We use while setting,
When a resin-made decorative form is used by setting it on a steel-made concrete form, there is a concern that the finished state of the concrete product can be affected because it can be set well in relation to the curvature accuracy.

As another method of manufacturing a decorative mold having a curved surface, a styrofoam decorative mold having a desired uneven pattern formed by slitting the mold so that it can be deformed to a certain extent, has a curved surface. There is a method of setting and using the concrete formwork. FIG. 4 is a schematic cross-sectional view of a conventional slit-shaped decorative formwork 20 (A).
Shows a state in which a slit 22 is formed in the styrofoam decorative mold frame 20, and (B) shows a state in which the styrofoam decorative mold frame 20 is bent to form a curvature.

[0008] In this method, a smooth curvature cannot be expressed, and a large deformation may cause breakage. In addition, this method also has a problem of curvature accuracy when used by setting it on a steel concrete form as in the case of the above-mentioned resin decorative form.

Conventionally used decorative molds are made of hard resin, and (1) it is difficult to manufacture decorative molds due to equipment other than a specialized manufacturer. Molds have poor mold release properties of concrete and require a mold release agent. (3) Uneven patterns other than those with a demolding gradient cannot be removed, and moldable irregular patterns are also commercially available patterns. The range of choice is limited, (4) Hard resins are mostly thermosetting and reaction curable, and cannot be reused,
And the like. Furthermore, these drawbacks were more pronounced when used with curved surfaces than with flat plates.

[0010] That is, it is impossible to recycle the decorative form using the conventional decorative form, and furthermore, the desired form is formed on the surface.
That is, in order to form a concave and convex pattern outside the range of the existing decorative form that can be supplied by the manufacturer, or to manufacture a concrete product having a curved surface, a special order for the decorative form is necessary,
It was costly and not easy.

For this reason, it is conceivable to use a transfer mold made of gypsum, but it is easy to manufacture a gypsum mold by forming an arbitrary uneven pattern or a curved surface, but it is damaged when the concrete is removed from the mold. Therefore, there is a problem that the use is limited to one use.

That is, in the conventional decorative formwork, the production of a concrete product having a desired uneven pattern on the surface and having a desired curved surface cannot be easily handled in a concrete product factory or the like. Was.

[0013]

DISCLOSURE OF THE INVENTION The present invention has been made in view of the above-mentioned circumstances, and it is possible to easily produce a concrete product having a desired uneven pattern on its surface, and it can be reused and recycled. A decorative formwork for concrete that can be easily manufactured without requiring special equipment, a concrete product having a desired uneven pattern formed on a surface manufactured using the decorative formwork, and its simple and good workability The aim is to provide a method.

[0014]

Decorative mold of the present invention In order to achieve the above object, according to a concrete cosmetic formwork to form the uneven pattern on the surface of the concrete, as a main component a polymer organic material and a low molecular material, the Volume in the main component of high molecular organic material
The polymer organic material is composed of a polymer blend material having a fraction of 30% or less, and the polymer organic material has a crystal structure or an aggregate structure.
Amorphous parts such as hard blocks that are easy to form
It is characterized by using a thermoplastic material having a three-dimensional continuous network skeleton structure having a soft block such as a structure together .

[0015] The thermoplastic material for a decorative frame (hereinafter, appropriately referred to as a material for a frame) used herein is composed mainly of a high-molecular organic material and a low-molecular material,
Volume fraction in the component is configured using the polymer blend material is 30% or less, and, the polymeric organic material is sintered
Easy to form hard block such as crystal structure or aggregate structure
And a soft block such as an amorphous structure
It is configured using a polymer blend material having a three-dimensional continuous network skeleton structure.

Further, in the decorative formwork for concrete of the present invention, the polymer blend material has a number average molecular weight of 4
0,000 or more high molecular weight organic materials and the number average molecular weight 5,0
It is characterized by having a low molecular weight material of less than 00 as a main component, and a difference in solubility parameter between the high molecular weight organic material and the low molecular weight material is 3.0 or less.

Further, the high-molecular organic material includes :
Between tadiene and butadiene-styrene random copolymer
Polyethylene and ethylene obtained by hydrogenating a block copolymer
Blow with Tylene / butylene-styrene random copolymer
(2) Polybutadiene and polystyrene
Block copolymer, or polybutadiene or ethylene
Of styrene-butadiene random copolymer and polystyrene
Polyethylene / butyl obtained by hydrogenating a block copolymer
Block copolymer of styrene and polystyrene, (3)
Crystalline end at one or both ends of the styrene / butylene copolymer
(4) Ethylene-
Propylene rubber, especially polyethylene and ethylene
/ Block copolymer with butylene-styrene random copolymer
It is preferably at least one selected from polymers .

The mold material is prepared by using the above-mentioned high-molecular organic material and adjusting the kind and the amount of the low-molecular material to be used in combination, so as to have a melting temperature of 70 to 120 ° C. be able to.

A concrete product according to the present invention is formed by using the decorative formwork for concrete according to the first aspect, and has an uneven pattern formed on the surface.

Further, the method for producing a concrete product according to the present invention is a method for producing a concrete product having an uneven pattern on its surface, wherein (1) the decorative formwork for concrete according to claim 1 is cast in concrete. (2) a step of placing concrete inside the concrete casting formwork, and (3) a step in which the poured concrete hardens and develops a desired strength. Curing, and (4) removing the mold after the concrete is hardened, and peeling off the decorative mold for concrete made of the thermoplastic material for decorative form attached to the surface.

Further, the concrete casting formwork may have a curved surface.

[0022]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below in detail.

The thermoplastic material for the decorative formwork constituting the decorative formwork of the present invention mainly comprises a high molecular weight organic material and a low molecular weight material. The high molecular weight organic material has a number average molecular weight of 4 %.
More than 000 thermoplastic high molecular organic materials and their
Rubber modified products and the like can be mentioned.

Specific examples of the thermoplastic high molecular organic material include those having both a portion where a hard block such as a crystal structure and a cohesive structure is easily formed and a soft block such as an amorphous structure. Preferably, specifically, the following are mentioned.

A block copolymer of polyethylene and an ethylene / butylene-styrene random copolymer obtained by hydrogenating a block copolymer of polybutadiene and a butadiene-styrene random copolymer.

A block copolymer of polybutadiene and polystyrene, or a block copolymer of polyethylene / butylene and polystyrene obtained by hydrogenating a block copolymer of polybutadiene or an ethylene-butadiene random copolymer and polystyrene .

A block copolymer in which crystalline ethylene is linked to one end or both ends of an ethylene / butylene copolymer.

[0028] Ethylene-propylene rubber. Of these, a block copolymer of polyethylene and an ethylene / butylene-styrene random copolymer is particularly preferred.

These various kinds of thermoplastic polymer organic materials are mainly used alone, but two or more kinds thereof may be blended and used.

On the other hand, the low-molecular material preferably has a viscosity at 100 ° C. of 1 × 10 ⁵ centipoise or less , and from the viewpoint of molecular weight, the number-average molecular weight of the low-molecular material is particularly 5,000. The following is preferred. Usually, a liquid or liquid material at room temperature is suitably used as such a low molecular material. In addition, any of hydrophilic and hydrophobic low-molecular materials can be used, but from the viewpoint of releasability from concrete, hydrophobic low-molecular materials are preferable.

The low molecular weight material is not particularly limited,
The following are preferably exemplified. Softeners: Softeners for various rubbers or resins, such as mineral oils, vegetable oils, and synthetic oils. Examples of the mineral oils include aromatic, naphthenic, and paraffinic process oils. Vegetable oils include castor oil, cottonseed oil, sweet oil, rapeseed oil, soybean oil, palm oil, palm oil,
Peanut oil, wood wax, pine oil, olive oil and the like.

Plasticizers: Various ester-based plasticizers such as phthalic acid ester, phthalic acid mixed ester, aliphatic dibasic acid ester, glycol ester, fatty acid ester, phosphate ester, stearic acid ester, epoxy-based plasticizer, etc. Plasticizers for plastics or phthalates, adipates, sebacates, phosphates,
NBR plasticizers such as polyethers and polyesters.

Tackifiers: Various tackifiers (tackifiers) such as coumarone resins, coumarone-indene resins, phenol terpene resins, petroleum hydrocarbons, and rosin derivatives.

Oligomer: crown ether, fluorine-containing oligomer, polyisobutylene, xylene resin, chlorinated rubber, polyethylene wax, petroleum resin, rosin ester rubber, polyalkylene glycol diacrylate,
Various oligomers such as liquid rubbers (polybutadiene, styrene-butadiene rubber, butadiene-acrylonitrile rubber, polychloroprene, etc.), silicone oligomers, and poly-α-olefins.

Lubricants: hydrocarbon lubricants such as paraffin and wax; fatty acid lubricants such as higher fatty acids and oxy fatty acids; fatty acid amide lubricants such as fatty acid amides and alkylene bis fatty acid amides; fatty acid lower alcohol esters; fatty acid polyhydric alcohol esters , Ester lubricants such as fatty acid polyglycol esters, fatty alcohols,
Various lubricants such as alcoholic lubricants such as polyhydric alcohol, polyglycol and polyglycerol, metal soaps, and mixed lubricants.

In addition, latex, emulsion, bituminous composition, clay, inorganic silicone oil, phosphazene and the like are also suitable as low molecular weight materials.

Further, organic solvents such as hydrocarbons, halogenated hydrocarbons, alcohols, phenols, ethers, acetals, ketones, fatty acids, esters, nitrogen compounds and sulfur compounds, and petroleums , Water, an aqueous solution and the like can be used in combination to adjust the physical properties.

These low-molecular materials may be used alone or in a combination of two or more. In the present invention, in order to obtain a polymer blend material containing a large amount of the low molecular weight material with a large amount of the low molecular weight material and a smaller amount of the high molecular weight organic material, each of the low molecular weight material and the high molecular weight organic material is used. A difference in solubility parameter value δ = (ΔE / V) ^1/2 (ΔE = molar evaporation energy, V = molar volume) of 3.0 or less;
It is preferable to select both materials so as to be preferably 2.5 or less. If this difference exceeds 3.0, it is difficult to maintain a large amount of low molecular weight material due to the compatibility of the two materials, which hinders the lowering of the elasticity of the obtained polymer blend material. It is not preferable because it easily occurs.

Further, in order to prevent the mold material from cracking after hardening and to facilitate peeling from the concrete product, it is necessary that the material for the formwork has optimum shear, tensile strength and elongation characteristics as described later. Therefore, it is necessary that the high-molecular organic material constituting the high-molecular-weight blend material of the mold material should form a three-dimensional continuous network skeleton structure,
The average diameter of the reticulated skeleton is 50 μm or less, preferably 30 μm or less.
μm or less, the average diameter of the cells (mesh) is 500 μm or less,
When the volume fraction of the high-molecular-weight organic material is defined as [volume of high-molecular-weight organic material / (volume of high-molecular-weight organic material + volume of low-molecular-weight material)] × 100 (%), The volume fraction of the molecular organic material is 30% or less, especially 2
It is desirable that it is 5% or less.

The polymer blend material may contain a predetermined amount of a high molecular organic material and a low molecular material, and if necessary, other compounding agents. The high molecular organic material may form a three-dimensional continuous network skeleton structure. It can be obtained by mixing under mixing conditions. In this case, it has a uniform three-dimensional continuous network skeleton structure made of a high-molecular-weight organic material, low bleeding of a low-molecular-weight material, and a high-quality material that satisfies the aforementioned characteristics. In order to obtain a molecular blend material, it is preferable to use a high-shear mixer as the mixer, and in particular, a mixer capable of providing a high shear force and a high shear rate between a fixed wall and a rotating rotor. , The distance (clearance) between the fixed wall and the rotating part (rotor) is t (m), and the rotating peripheral speed of the rotor is v
(M / sec) and the shear rate of the rotor as V,
When V = v / t (sec ^-1 ), V ≧ 5.0 × 10 ² (sec ⁻¹ ), preferably V ≧ 1.0 × 10 ³ (sec ⁻¹ ), and more preferably V ≧ 2. It is advantageous to use a special high-shear mixer that satisfies 5 × 10 ³ (sec ⁻¹ ), more preferably V ≧ 5.0 × 10 ³ (sec ⁻¹ ).

The polymer blend material according to the present invention is not particularly limited, such as a normal bulk shape, a gel shape, a foam shape, etc., but is in a gel state, in particular, a three-dimensional continuous uniform material made of a thermoplastic polymer organic material. Those in a gel state having a network skeleton structure are particularly effective for the present invention.

The physical properties of the mold material after curing are as follows.
The tensile strength evaluated in the tensile test of JIS K6301 is 0.5 kg / cm ² or more, and the elongation at break is 300
% Is preferred from the viewpoint of workability when peeling from the concrete product after curing.

The mold material is made of a high-molecular organic material as described above, and the melting temperature is adjusted to, for example, 70 to 50% by adjusting the type and amount of the low-molecular material.
Although it is possible to prepare those in the range of 120 ° C,
In consideration of the case where the curing of the concrete is performed by heating, it is preferable to use one having a melting temperature of 100 to 120 ° C.

Next, a method of forming a concavo-convex pattern of a decorative mold frame according to the present invention will be described. Unlike the hard resin, the mold material used for the decorative mold of the present invention hardens into an elastic solid, so that the decorative mold can be easily manufactured.

First, a prototype of a desired concavo-convex pattern is prepared, the material for the mold is heated to a melting temperature or higher, and the concavo-convex pattern of the prototype is transferred using an oily material. Examples of the transfer method include a method in which a mold is poured into a mold on which the mold is laid, a method in which a molten mold material is placed in a container, and the mold is immersed therein and the mold material is cured as it is.

There is no particular limitation on the formwork on which the desired concavo-convex pattern is formed, and a formwork on which a flat plate provided with a relief of a desired design is arranged on the bottom surface, and a log for forming a pseudo-wood surface are laid out. It is appropriately selected according to the intended design, such as a mold frame, a mold frame on which natural stones are arranged for forming a raised and recessed pattern of stone on the surface.

As a method of heating the material for the formwork, for example,
Put in a container, heat the container with a direct fire, a heater, heat in a dryer, heat in a microwave, heat in a microwave, heat in a steam, heat in a sand bath, oil bath, etc. Although there is no particular limitation, it is preferable to employ a method of heating with steam from the viewpoint that temperature control is reliable and uniform heating is possible.

The mold material melted in an oily state has a low viscosity, excellent fluidity, and good shape followability as compared with the melted state of a conventional thermoplastic resin or thermosetting resin. The mold material is uniformly filled up to the details of the concave and convex portions of the concave-convex pattern prototype, and a decorative mold that accurately reproduces the details of the prototype shape can be created. Furthermore, since the length of the mold material hardly changes between when it is heated and melted and when it is cooled and hardened, it has excellent physical properties that there is no problem of reproducibility of the original shape being reduced due to thermal contraction or thermal expansion. .

The injection of the mold material melted in an oily state
It is performed so as to have a thickness necessary for molding the decorative formwork.
At this time, in order to improve the surface strength of the plate-shaped decorative form,
A flexible reinforcing material, for example, a lath material or the like, may be disposed in the formwork material in advance.

Thereafter, after the mold material is cooled to room temperature and cured, the mold material is removed from the mold, or the mold material hardened while the original is immersed therein is divided into a plurality of portions at appropriate portions. The prototype is taken out and used as a decorative frame.

The mold material melts when heated and exhibits a low-viscosity oily state, but becomes solid when cooled to room temperature. Therefore, the curing of the mold material can be performed by leaving the mold at room temperature. In addition, in order to improve workability, the mold can be positively cooled and cured by placing the mold in a low-temperature storage.

The thus obtained cured body of the mold material of the present invention is used by placing it in a holding concrete forming mold (hereinafter, appropriately referred to as a concrete mold) as required.

When manufacturing a flat plate such as a concrete plate having an uneven pattern formed only on the surface, the uneven pattern is transferred and
The formed decorative form is used by laying it on the bottom of a concrete form such as a concrete plate forming form. If a concrete formwork having a curved surface is used, a concrete product having a curved surface and having an uneven pattern on the surface of the curved surface can be manufactured.

The decorative form removed from the concrete product can be used repeatedly as it is, but it can also be melted and remolded for use in other patterns and shapes.

That is, the thermoplastic material constituting the decorative formwork of the present invention is heated and melted to precipitate impurities such as mixed release agent, cement, sand, water, dust and the like, and is easily separated and removed. be able to. Therefore, it is easy to use (recycle) again.

Next, the concrete product of the present invention will be described. The concrete product of the present invention is manufactured by using the decorative form, and the decorative form is, as described above, an appropriate concrete form. It may be arranged in a frame.

[0057] In order to produce the concrete product of the present invention, the concrete to be poured into the decorative formwork may have any composition according to the purpose of use of the concrete product. Also, the casting method can be performed by a conventional method. That is, ordinary cement concrete, prestressed concrete (PC), lightweight cellular concrete, or the like can be used. In the case of manufacturing a concrete product of a fixed shape such as a flat plate or an L-shaped retaining wall, a reinforcing material is put in advance to manufacture. You can also.

The curing after the concrete is poured into the decorative formwork of the present invention may be normal temperature curing or high temperature curing.

From the viewpoint of workability, high-temperature curing is preferable.
Since the temperature of steam curing usually performed is 60 to 70 ° C, if a material having a melting temperature of 100 to 120 ° C is used,
Performing high-temperature steam curing under normal conditions does not affect the thermoplastic material constituting the decorative formwork.

When performing high-temperature curing other than steam curing, the upper limit of the heating temperature should be around the melting temperature of the decorative form material in order to prevent deformation of the decorative form. preferable.

After the poured concrete has hardened, it is released from the mold to obtain a concrete product having an uneven pattern formed on its surface. The material for the decorative form is a three-dimensional continuous and uniform material made of a thermoplastic polymer organic material. Since the low molecular weight material is held in the reticulated skeleton structure, when the hydrophobic low molecular weight material is held, the whole material becomes hydrophobic, and the mold release property from the concrete is good. A concrete product having a desired concavo-convex pattern can be obtained without leaving concrete on the surface. Therefore, it is not necessary to perform a pre-treatment such as application of a release agent or a post-treatment such as removal of remaining concrete, and the decorative mold can be reused.

Moreover, the entire mold material is a rubber-like elastic material held by a polymer network skeleton structure, and can be elastically deformed and has sufficient strength against tensile stress.
The decorative formwork can be easily peeled off from a large area flat plate or three-dimensional concrete product at a time. Can be easily separated.

By using the decorative formwork of the present invention, an arbitrary uneven pattern can be formed on the surface of a concrete PC plate, a curtain wall, a concrete L-shaped retaining wall, a sidewalk concrete block, a concrete fence, etc. in addition to a concrete flat plate. It is also possible to easily manufacture a concrete product made of, for example, a three-dimensional concrete product imitating a shape such as a log.

The method for producing a concrete product of the present invention comprises:
First, (1) the decorative formwork is arranged on the inner surface of the concrete casting formwork. The features and the manufacturing method of the decorative formwork are as described above.

The concrete casting form used here may be a flat plate or a semi-cylindrical plate having one curved surface, in which a plurality of gentle curved surfaces are continuously formed. It may be something. The obtained decorative form is
Because it can be elastically deformed, it can be perfectly adapted to any concrete formwork, so there is no problem of curvature accuracy as in the case of hard resin formwork. It is possible to deform a plate-shaped decorative form, and to manufacture various modified examples of concrete products, thereby improving workability.

Next, (2) concrete is poured into the concrete casting formwork on which the decorative formwork is arranged,
(3) Curing is performed until the cast concrete hardens and develops the desired strength, but (2) to (3) can be performed in the same manner as described for the concrete product.

Next, (4) after the concrete has hardened, the concrete is first released from the concrete casting mold, and then the concrete decorative mold that has been removed while being attached to the hardened concrete surface is removed. The concrete product is manufactured by peeling, that is, removing the concrete from the decorative formwork. The decorative form used in this manufacturing method is
It is a plate-shaped decorative form made of the decorative form forming thermoplastic material, and can be easily peeled off from the concrete surface as a single sheet, regardless of whether the concrete product has a flat surface or a curved surface. .

The use of the concrete product to which the decorative formwork of the present invention can be applied is not particularly limited, and is used for construction (decorative panels for interior and exterior of buildings, decorative columns, floors, etc.) and civil engineering (road pavement). , Decorative panels for wall surfaces, etc.), decorative objects (log-shaped benches, exterior products, objects, etc.) and the like.

Further, by applying the method for manufacturing a concrete product of the present invention, in addition to a flat plate, a concrete flat plate having a curved surface such as a corrugated shape and having an uneven pattern on its surface, a concrete cylinder, a semi-column, and the like can be used. , Concrete PC
It has a curved surface such as a plate, a curtain wall, a concrete L-shaped retaining wall, a sidewalk concrete block, a concrete fence and the like, and imitates a concrete product having an arbitrary uneven pattern formed on the surface or a shape such as a log. Like
A three-dimensional concrete product having a curved surface can also be easily manufactured.

[0070]

EXAMPLES The present invention will be described below in detail with reference to examples, but the present invention is not limited to these examples. (Example 1) (1) Preparation of thermoplastic material A for decorative frame As a raw material, polyethylene obtained by hydrogenating a block copolymer of polybutadiene and a butadiene-styrene random copolymer, which are high-molecular organic materials, Block copolymer (high molecular weight organic material) of ethylene and ethylene / butylene-styrene random copolymer (number average molecular weight 150,000: SP value 8.2) to 15% by volume of low molecular weight alkylbenzene (softening agent) ) (Z-300, manufactured by Nippon Sun Oil Co., Ltd .: molecular weight: 335, SP value: 8.3) 42.5% by volume and diisodecyl diadipate (plasticizer) (DIDA, manufactured by Daihachi Chemical Co .: molecular weight: 426, SP value: 8.) 4) 42.5% by volume;
And a high-shear type special mixer ("TK. Auto Homomixer" manufactured by Tokushu Kika Kogyo Co., Ltd.) for 30 rpm.
The mixture was mixed under mixing conditions of 00 rpm, a shear rate of 1.0 × 10 ⁴ / sec, a mixing temperature of 180 ° C., and a mixing time of 40 minutes to obtain a polymer blend material having a uniform appearance. did. When a section of the polymer blend material was cut out and confirmed with an optical microscope, a three-dimensional continuous network skeleton structure (average diameter of skeleton of 5 μm, average diameter of cell of 15 μm) composed of a thermoplastic polymer organic material was formed. It was confirmed that. Further, Asker-C hardness of this polymer blend material is 10, tensile strength is 3 kg / cm ² ,
Elongation at break is 1500%, compression set (70 ° C, 2
2 hours) was 30, and the melting temperature was 120 ° C. (2) Production of decorative formwork The thermoplastic material A for decorative formwork was melted at 170 ° C, the surface of a wood log was transferred and cooled to room temperature, to produce a decorative formwork for a pseudo-wooden concrete product.

FIG. 1 is a schematic sectional view of a decorative mold 10 of the present invention. The decorative mold 10 is made of a thermoplastic material A for a decorative mold.
The surface is formed with an embossed pattern 14 of a fake wood design.

FIG. 2 is a schematic cross-sectional view showing a state in which the decorative formwork 10 is disposed in a holding steel formwork (concrete casting formwork) 16. (3) Manufacture of concrete product The obtained decorative mold 10 is placed in a concrete casting mold 16 and concrete is cast by a usual method.
After steam curing for 3 hours to cure the concrete, first remove it from the concrete casting mold 16 and then peel off the decorative mold 10 disposed on the hardened concrete product surface. , Demolished concrete products.

It was observed that the obtained concrete product had a pseudo-wood pattern 14 formed on the surface, and the surface accurately reproduced the pattern of the original log surface.
It was possible to produce a concrete product with excellent appearance.

Further, concrete was clearly removed from the surface of the thermoplastic material A12 constituting the decorative formwork 10, and no concrete remained on the surface of the decorative formwork was observed. (Example 2) (4) Regeneration of the decorative formwork The decorative formwork of Example 1 is heated and melted, and the mixed impurities are precipitated from the oily thermoplastic material A for the decorative formwork again. Removed.

Using the oil-like thermoplastic material A for a decorative form, the flat iron stone placed in the form was transferred to form a flat decorative form. The obtained decorative form was placed in a holding steel form, and a concrete product was manufactured in the same manner as in Example 1.

A concrete flat plate having an embossed pattern of stone on the surface was obtained. The resulting concrete product was observed to have an embossed pattern of stones on the surface, and it was observed that the surface accurately reproduced the original turbulent iron flat stone. Could be manufactured.

Further, the thermoplastic material A constituting the decorative mold
Concrete has been cleanly removed from the surface of the concrete form, and no concrete remains on the decorative form surface and no deterioration of the decorative form has been observed even in the uneven pattern portion having a 90 ° angle without a demolding slope. Was.

Using this decorative mold, a concrete product was manufactured 30 times repeatedly. When the surface of the decorative formwork was observed, no concrete remained on the surface of the decorative formwork even after 30 repetitions, and the obtained concrete product accurately reproduced the turbulent iron slab. Thus, it was found that the decorative formwork of the present invention had excellent durability against repeated use. (Example 3) (1) Preparation of thermoplastic material B for decorative frame Polyethylene obtained by hydrogenating a block copolymer of polybutadiene and a butadiene-styrene random copolymer, which are high-molecular organic materials, as raw materials Block copolymer (high molecular weight organic material) of ethylene and ethylene / butylene-styrene random copolymer (number average molecular weight: 150,000; SP value: 8.2) 10% by volume, and alkylbenzene (softening agent)
(Z-300, manufactured by Nippon Sun Oil Co., Ltd .: molecular weight 335, SP
Value 8.3) 42.5% by volume and diisodecyl diadipate (plasticizer) (DIDA, manufactured by Daihachi Chemical Co .: molecular weight 426,
SP value 8.4) 42.5% by volume, and further 5% by volume of higher fatty acid amide (oleic acid amide Armoslip: manufactured by Lion) were added, and a special high-shear mixer ("TK Auto Homo") was added. Mixer ”Tokushu Kika Kogyo Co., Ltd.
3,000 rpm, shear rate 1.0 ×
The mixture was mixed under a mixing condition of 10 ⁴ / sec, a mixing temperature of 180 ° C., and a mixing time of 40 minutes to obtain a polymer blend material having a uniform appearance. Further, a section of this polymer blend material was cut out and confirmed by an optical microscope. As a result, a three-dimensional continuous network skeleton structure (average skeleton diameter of 3 μm, average cell diameter of 1 μm) made of a thermoplastic high molecular organic material was obtained.
8 μm) was confirmed to be formed. The polymer blend material has an Asker-C hardness of 10, a tensile strength of 3 kg / cm ² , an elongation at break of 1500%, a compression set (70 ° C., 22 hours) of 30 and a melting temperature of 1
20 ° C. (2) Production of decorative formwork The thermoplastic material B for decorative formwork was heated and melted at 170 ° C, and a decorative formwork was prepared in the same manner as in Example 1. (3) Production of concrete product A concrete product was produced in the same manner as in Example 1 using this decorative formwork.

In the obtained concrete product, it was observed that a pseudo-wood pattern was formed on the surface, and it was observed that the surface accurately reproduced the original log surface, thereby producing a concrete product excellent in appearance. I was able to.

Further, the thermoplastic material B constituting the decorative formwork
The concrete was completely removed from the surface of the decorative formwork, and no concrete remained on the surface of the decorative formwork.

A concrete product was manufactured 30 times by using the decorative mold, and no concrete remained in the decorative mold, deterioration of the decorative mold and deterioration of appearance of the concrete product were observed.

Example 4 (1) Preparation of Thermoplastic Material C for Decorative Mold As a raw material, a block copolymer containing polyethylene, which is a high-molecular organic material, at both ends and containing ethylene-butylene in the center ( High-molecular-weight organic material) (number-average molecular weight: 280,000:
90% by volume of paraffin oil (softening agent) (PW-32, manufactured by Idemitsu Kosan Co., Ltd .: molecular weight 405, SP value of 7.9), which is a low molecular weight material, is added to 10% by volume of SP value 8.0) and a high shearing type Using a special mixer (“TK Auto Homomixer” manufactured by Tokushu Kika Kogyo Co., Ltd.), the number of revolutions is 3000 rpm, the shearing speed is 1.0 × 10 ⁴ sec, the mixing temperature is 180 ° C., and the mixing time is 40 minutes. To obtain a polymer blend material having a uniform appearance, which was used as a thermoplastic material C for a mold. When a section of the polymer blend material was cut out and confirmed with an optical microscope, a three-dimensional continuous network skeleton structure (average diameter of skeleton of 5 μm, average diameter of cell of 15 μm) composed of a thermoplastic polymer organic material was formed. It was confirmed that. Further, Asker-C hardness of this polymer blend material is 2, tensile strength is 1.2 kg / cm ² , elongation at break is 970%, compression set (70 ° C., 22 hours) is 50,
The melting temperature was 110 ° C. (2) Production of decorative formwork The thermoplastic material C for decorative formwork was heated and melted at 170 ° C, and a decorative formwork was prepared in the same manner as in Example 1. (3) Production of concrete product A concrete product was produced in the same manner as in Example 1 using this decorative formwork.

The resulting concrete product was observed to have a pseudo-wood pattern on its surface, and it was observed that the surface accurately reproduced the original log surface, producing a concrete product with excellent appearance. I was able to.

Further, the thermoplastic material C constituting the decorative mold is
The concrete was completely removed from the surface of the decorative formwork, and no concrete remained on the surface of the decorative formwork.

A concrete product was manufactured by repeating this process 30 times using the decorative mold, but no concrete remained in the decorative mold and no deterioration in the appearance of the concrete product was observed.

(Example 5) (1) Production of a decorative formwork A decorative formwork prepared in the same manner as in Example 1 was placed in a mold 32 for forming a decorative formwork in which logs 30 as a prototype were laid in advance. The thermoplastic material A12 is melted at 170 ° C. and made into an oily state, and injected to a predetermined position (FIG. 3A).

After leaving this at room temperature to cure the thermoplastic material A12 for decorative form, the mold is removed from the mold to obtain a plate-like decorative form 36 having a log 30 with a pseudo-wood pattern on the surface [ FIG. 3 (B)].

The decorative formwork 36 is placed on the inner surface of a concrete casting formwork 38 having a curved surface with a curvature of 50 cm. The decorative formwork is made of a thermoplastic material A12 for decorative formwork and has rubber-like elasticity, so that it fits perfectly with the inner surface of the concrete casting formwork 38 having a curved surface.
A smooth curved surface can be formed. (2) Manufacture of a concrete product A concrete casting formwork 38 having an uneven pattern on its surface is arranged on the inner surface of a concrete casting formwork 38.
4 was cast in a conventional manner, steam-cured at about 70 ° C. for 3 hours, and the concrete was hardened and then released from the mold. FIG.
(C) is a schematic sectional view showing a state in which the concrete 24 is cast in the concrete casting formwork 38 in which the decorative formwork 36 is disposed.

Since the surface of the removed concrete product 40 is provided with a decorative mold 36 having an uneven pattern,
This is peeled off to obtain a concrete product 40 [FIG.
(D)].

It was observed that the pseudo-wood pattern of the log 30 as a prototype was accurately reproduced on the surface of the obtained concrete product 40, and the outer shape had a gentle curved surface.
The concrete product 40 excellent in appearance was able to be manufactured.

The concrete 24 did not adhere to the surface of the thermoplastic material A12 constituting the decorative formwork 36, and no residual concrete 24 was observed on the surface of the decorative formwork 36. (Example 6) (3) Regeneration of the decorative formwork The decorative formwork 36 of Example 5 is heated and melted, and the mixed impurities are precipitated from the oily thermoplastic material A for the decorative formwork again. To remove. Using the oil-form thermoplastic material A for decorative form, the iron slab of turbulent iron arranged in the form was transferred, and a decorative form with an embossed pattern of iron slab was formed on the surface. . The obtained decorative mold was placed in the same concrete casting mold as in Example 5, and a concrete product was manufactured in the same manner as in Example 5.

A semi-cylindrical concrete product having a raised and recessed pattern of stone on the surface was obtained. The resulting concrete product has an embossed uneven pattern of stones formed on the surface, and the surface accurately reproduces the original turbulent iron flat stone, and the entire surface can form a gentle curved surface It was observed that a concrete product having an excellent appearance could be produced.

Further, the thermoplastic material A constituting the decorative mold
Concrete was completely removed from the surface of the decorative mold, and no residue of the concrete on the surface of the decorative formwork and deterioration of the mold were observed even in the uneven pattern portion having an angle of 90 ° without the removal gradient.

[0094] By re-arranging the decorative formwork in a concrete formwork having a curved surface, a similar concrete product was repeatedly produced 30 times. When the surface of the decorative form was observed, no concrete remained on the surface of the decorative form even after 30 repetitions, and the obtained concrete product accurately reproduced the turbulent iron slab. Since a concrete product having excellent appearance was obtained, it was found that the decorative formwork according to the present invention had excellent durability against repeated use.

(Example 7) (1) Production of decorative formwork The thermoplastic material B for decorative formwork obtained in Example 3 was used
It was heated and melted at 70 ° C., and a decorative formwork was prepared in the same manner as in Example 5 and placed in a concrete casting formwork having a curved surface. (2) Production of concrete product A concrete product was produced in the same manner as in Example 5 using this formwork. The obtained concrete product was observed to have a pseudo-wood pattern on the surface, and it was observed that the surface accurately reproduced the original log surface, and the concrete product outer shape had a gentle curved surface, It was possible to produce a concrete product with excellent appearance.

Further, the thermoplastic material B constituting the decorative formwork
The concrete was completely removed from the surface of the decorative formwork, and no concrete remained on the surface of the decorative formwork.

A concrete product was manufactured by repeating this process 30 times using the plate-shaped decorative form and the concrete form having a curved surface, but no residual concrete on the decorative form and no deterioration in the appearance of the concrete product were observed. .

Further, it was confirmed that, similarly to the thermoplastic material A for decorative formwork in Example 1, the thermoplastic material B for decorative formwork can be recycled by melting and removing impurities.

(Example 8) (1) Production of decorative formwork The thermoplastic material C for decorative formwork prepared in the above Example 4 was prepared as follows.
It was heated and melted at 70 ° C., and a decorative formwork was prepared in the same manner as in Example 5 and placed in a concrete casting formwork having a curved surface. (2) Manufacture of concrete product Using this decorative mold, a concrete product was manufactured in the same manner as in Example 5.

The obtained concrete product was observed to have a pseudo-wood pattern on its surface, and it was observed that the surface accurately reproduced the original log surface, and the concrete product had a gentle curved surface. As a result, it was possible to produce a concrete product having an excellent appearance.

Further, the thermoplastic material C constituting the decorative mold is
The concrete was completely removed from the surface of the decorative formwork, and no concrete remained on the surface of the decorative formwork.

A concrete product was manufactured 30 times by using the plate-shaped decorative form and the concrete form having a curved surface, but no concrete remained on the decorative form and deterioration of the appearance of the concrete product was observed. Was.

Further, it was confirmed that, similarly to the thermoplastic material A for decorative formwork in Example 1, the thermoplastic material C for decorative formwork can be recycled by melting and removing impurities.

[0104]

As described above, according to the decorative mold of the present invention, it is possible to manufacture a concrete product having a desired uneven pattern on its surface, and the decorative mold itself can be reused and recycled. It has an excellent effect that it can be easily manufactured without requiring special equipment. Moreover, the concrete product manufactured by using the decorative formwork can form a desired uneven pattern on the surface, and has an effect of being excellent in appearance. Further, according to the method for producing a concrete product of the present invention, in addition to a flat plate, a concrete product having a curved surface and having a desired uneven pattern formed on the surface can be produced with good workability. It is.

[Brief description of the drawings]

FIG. 1 is a schematic sectional view showing a decorative formwork of Example 1.

FIG. 2 is a schematic cross-sectional view showing a state where the decorative formwork of Example 1 is arranged in a concrete formwork.

FIG. 3 is a schematic cross-sectional view illustrating a method for manufacturing a concrete product of Example 5, in which (A) injects a mold material into a mold for forming a decorative mold in which a desired uneven pattern is formed in advance. (B) shows the obtained decorative form, (C)
(D) shows a state in which the decorative formwork is placed in a concrete casting formwork having a curved surface and concrete is poured.
Indicates the obtained concrete product.

FIG. 4 is a schematic cross-sectional view of a conventional slit-formed formwork, in which (A) shows a state in which the styrofoam form is slit, and (B) shows a curved surface formed by bending the styrofoam form. It shows the state where it was done.

[Explanation of symbols]

 Reference Signs List 10 decorative formwork 12 thermoplastic material for decorative formwork 16 concrete placing formwork (steel formwork for holding) 24 concrete 36 decorative formwork 38 concrete placing formwork having a curved surface 40 concrete product

──────────────────────────────────────────────────続 き Continuing from the front page (72) Inventor Hiroaki Suzuki 7-1-55 Minamienkajima, Taisho-ku, Osaka-shi, Osaka Sumitomo Osaka Cement Co., Ltd. Central research institute (72) Inventor Shusuke Harada Minami, Taisho-ku, Osaka, Osaka 7-1-55 Enkajima Sumitomo Osaka Cement Co., Ltd. Central Research Laboratory (72) Inventor Masao Kusano 7-1-55 Minamienkajima, Taisho-ku, Osaka-shi, Osaka Sumitomo Osaka Cement Co., Ltd. Central Research Laboratory (72) Inventor Tachibana Kikuo 7-1-55 Minami-enkajima, Taisho-ku, Osaka-shi, Osaka Sumitomo Osaka Cement Co., Ltd. Central Research Laboratory (56) References JP-A-4-173105 (JP, A) JP-A-3-205103 (JP, A) JP-A-5-147013 (JP, A) (58) Fields investigated (Int. Cl. ⁷ , DB name) B28B 7/16 B28B 1/14

Claims (6)

(57) [Claims] 1. A concrete cosmetic formwork to form the uneven pattern on the surface of the concrete, as a main component a polymer organic material and a low molecular weight material, the polymer
The volume fraction of the main component of the organic material is 30% or less.
A hard block composed of a certain polymer blend material, wherein the high-molecular organic material has a crystal structure, an aggregate structure, or the like.
Parts that are easy to form
A decorative formwork for concrete, characterized by using a thermoplastic material having a three-dimensional continuous network skeletal structure, which is held together with a mold. 2. The polymer blend material according to claim 1, wherein the polymer blend material has a number average molecular weight of 40,000 or more and a number average molecular weight of
2. The concrete according to claim 1, wherein a difference in solubility parameter between the high-molecular-weight organic material and the low-molecular-weight material is 3.0 or less, the low-molecular-weight material being less than 5,000 as a main component. Makeup formwork. 3. The polymer organic material comprises: (1) polybutadiene and butadiene-styrene random copolymer;
Polyester obtained by hydrogenating a block copolymer with a polymer
Tylene and ethylene / butylene-styrene random copolymerization
(2) block copolymer of polybutadiene and polystyrene
Body or polybutadiene or ethylene-butadiene
Block copolymerization of random copolymer and polystyrene
Polyethylene / butylene and police obtained by hydrogenating the body
Block copolymers of styrene, on one or both ends of the (3) ethylene / butylene copolymer
Block copolymer crystalline ethylene are linked, (4) an ethylene - propylene rubber, of which in particular polyethylene
Tylene and ethylene / butylene-styrene random copolymerization
The decorative formwork for concrete according to claim 1, wherein the form is at least one selected from a block copolymer with a body . 4. A concrete product formed by using the decorative formwork for concrete according to claim 1 and having an uneven pattern formed on a surface thereof. 5. A method for producing a concrete product having an uneven pattern formed on its surface, comprising: (1) disposing the decorative formwork for concrete according to claim 1 on an inner surface of the concrete casting formwork; (2) a step of placing concrete in the concrete casting formwork; (3) a step of curing the placed concrete until it hardens and develops a desired strength; (4) the concrete Removing the decorative mold from the concrete after it has hardened, and removing the decorative formwork attached to the surface. 6. The method for manufacturing a concrete product according to claim 5, wherein the concrete casting form has a curved surface.